Foot construction and method



Sept. 5, 1967 .1. O'NEILL 3,339,210

' FOOT CONSTRUCTION AND METHOD 7 .Filed Sept. 27, 1966 2 Sheets-Sheet 1 amlwmmmzzmW Sept. 5, 1967 J O' EIL I 3,339,210

FOOT couswnucnou AND METHOD Filed Sept. 27, 1966 2 Sheets-Sheet mm; any) United States, Patent 3,339,210 FOOT CONSTRUCTION AND METHOD Joseph ONeill, Phoenixville, Pa., assignor to National Knitting Company, a corporation of Pennsylvania Filed Sept. 27, 1966, Ser. No. 582,403 7 Claims. (Cl. 2-80) This invention relates to a foot of a garment and more particularly to garments of two-way stretch material particularly suitable for young children.

Two-way stretch material having substantial transverse and longitudinal resilient stretchability has been used to 'make childrens garments of differing types; as for example, a childs garment shown in Patent Number 2,994, 884. Such garments are of the step-into type having fully enclosed feet and are preferably of the one-piece or twopiece type. In basic construction, the body of the garment has been formed of a front and a back panel of stretch material. Except for the enclosed feet, the garment may be simply constructed by stitching the front and back panels together along left and right side seams and inner leg seam and a shoulder seam, with arms being added if desired. However, in order to form each of the fully enclosed feet of the garment, a separate sole panel must be stitched along its entire circumference to the corresponding foot portion of the frontand back panels. The cutting of the sole panels and stitching them in place requires a relatively large amount of skilled hand labor and substantially increases the cost of making the garment. It has not heretofore been possible to construct a garment having fully enclosed feet without essentially hand tailorin-g each foot of the garment.

Accordingly, an object of the present invention is a garment having fully enclosed feet in which the feet are formed by the front and back panels of the garment, Without requiring separate sole panels.

Another object of the invention is a two-way stretch garment in which each foot portion is formed only by the front and back panels of the garment with simple sewing operations.

In accordance with the present invention, there is provided a garment made of two-way stretch material comprising a front panel and a back panel, with each panel having inside and outside surfaces. The front panel has a left and a right tongue-shaped extension respectively forming a part of the left and the right leg of the garment. Similarly, the back panel has a left and a right tongueshaped extension respectively, forming a part of the left and the right leg of the garment. A first fold is formed in each of the left and right back panel extensions with each first fold being in a direction to tend to bring the inside surfaces of the respective back panels together. A second fold is formed in each of the left and right back panel extensions closer to the toe end of the extension than the first fold with each second fold being in a direction to tend to bring the outside surfaces of the respective back panels together. In this manner, each second fold is in opposite direction to that of the corresponding first fold. The left and right front extensions are sewn to the left and right back extensions respectively to form left-and right enclosed leg and foot portions.

Thus, in accordance with the invention, in each leg portion (1) the first fold forms the back edge of the heel pocket (*2), between the first and second fold there is formed a substantial portion of the heel pocket and (3) front the second fold to the remainder of the extension in the direction of the toe end there is formed substantially the sole portion. Thus, there is provided fully enclosed feet in which the feet are formed by the front and back panels of the garment without requiring separate sole panels.

ice

For further objects and advantages of the present invention, reference is to be had to the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a rear elevational view of a garment bottom embodying the present invention;

FIGS. 2 and 3 are elevational views of the front and back panels respectively of the garment of FIG. 1;

FIGS. 4 and 5 are elevational views of the left back panel of FIGS. 1-3;

FIG. 6 is a perpective view of a finished leg and foot portion of FIG. *1 before turning inside out;

FIG. 7 is a finished leg and foot portion of FIG. 1 in which a leg and foot have been inserted.

Referring now to FIG. 1, there is shown the bottom portion of a two-piece garment 10 made of knitted stretch material. The stretch material is of the well-known type known in the art and is woven of a stretchable yarn in such a manner that the material has substantial transverse and longitudinal resilient stretchability. While the bottom of a two-piece garment has been shown, it will be understood that the present invention is also applicable to a one-piece garment.

Garment 10 comprises a one-piece front panel 12, shown in FIG. 2, and two back panels 13 and 14 shown in FIG. 3 with each of the panels being made of two-way stretch material. The front panel 12 has an inside surface and an outside surface with the outside surface being illustrated in FIG. 2. Front panel 12 has two elongated extensions or tongues 12a and 12b with extension 12a forming a part of the right leg of the garment, while extension 12b forms a part of the left leg of garment 10. Each of the extensions 12a and 12b tapers at the toe or lower end reaches its maximum Width at its crotch end or upper end. Notches 17a and 18m are formed on the outer edge and the inner edge toward the crotch respectively adjacent the toe end of extension 12a and substantially equidistant therefrom. Similarly, notches 17b and 18b are formed on the outer edge and the inner edge toward the crotch respectively of extension 12b adjacent the toe end of extension 12b and substantially equidistant therefrom. Closer to the crotch end of extensions 12a and 12b there are formed notches 19 and 20 in extensions 12a and 12b respectively at the crotch edge thereof. The purpose and specific spacings of the foregoing notches will later be described in detail.

Each of the back panels 13 and 14 has an inside surface and an outside surface with the inside surfaces being illustrated in FIG. 3. The right back panel 13 has an elongated extension or tongue 13a forming a part of the right leg of the garment. Similarly, back panel 14 has an elongated extension or tongue 14a forming a part of the left leg of the garment. Adjacent to the toe end of extension 13a there are formed notches 22a and 23a on the outside edge and on the inside crotch edge of extension 13a respectively. It will be noted that notch 23a is slightly closer to the toe end than notch 22a. Similarly, adjacent the toe end of extension 14a are formed notches 22b and 23b on the outside edge and the inside crotch edge of extension 14a respectively. It will be noted that notch 23b is somewhat closer to the toe end than notch 22b.

Closer to the crotch end of tongue 13a are formed notches 25a and 26a on the outer edge and the inner crotch edge of the extension respectively. Notch 26a is slightly closer to the toe end than notch 25a. Similarly, on extension 14a are formed notches 25b and 26b on the outer edge and the inner crotch edge of extension 14a respectively. Notch 26b is closer to the toe end. Each of the extensions 13a and 13b have a still further notch 28a and 28b formed respectively on the inner crotch edge of each extension and closer to the respective crotch end than previously described notches.

It will be noted that tongue 13a extends slightly outward in width between notches 22a and 25a to form a point'13b and between notches 23a and 26a to form a point 130. Similarly, tongue 14a extends slightly outward in width between notches 22b and 25b to form a point 14b and between notches 23b and 26b to form a point 14c. The purpose of the foregoing extension and the notches will become apparent from the following description.

As shown in FIG. 4, the left back extension 14a is folded at the upper pair of notches 25b and 26b which are closer than the other pair to the crotch end of the extension, with the direction of the first fold tending to bring the inside surfaces of the back panel together. This first fold forms the back edge 30 of the heel pocket of the enclosed foot. It will be seen that the maximum width of the folded over portion of extension 14a is somewhat less than the minimum width of the remaining portion of the extension 14a. It will be understood that the edge 30 in the first fold defines a line which is slightly further from the crotch end at the inner crotch edge of tongue 14a than at the outer edge. After the first fold is made, the folded over tongue portion may be held or temporarily stitched to the remaining tongue 14a portion only over the length between the first fold and the slightly extended width portion at points 14b and 140.

A second fold 32, FIG. is taken at points 14b and 140 of tongue 14a and positioned by notch 28b. Since the slightly extended portion at points 14b and 14c is located between the pairs of notches, it will be understood that after taking the second fold, notches 22b and 23b meet the other pair of notches, 25b and 26b. It will be understood by those skilled in the art that notch 28b is positioned to aid in the positioning of the second fold by the sewers.

Therefore, in accordance with the invention, a second fold 32 is made closer to the toe end of the tongue to tend to bring the outside surfaces of back panel 14a together. Thus, the second fold is taken in an opposite direction to the first fold which tends to bring the inside surfaces of the back panel together. The folds may now be stitched together adjacent the edges thereof between the first and second folds.

The back extension 14a is now ready to be sewn to the corresponding front left extension 12b with the extensions being sewn together along corresponding edges with the respective inner surfaces brought together and the outer surfaces being on the outside. The resultant foot construction which comprises only the front and back panels is shown in FIG. 6. It will now be understood that the extensions 14a and 12b are fitted together for sewing so that notch 18b is adjacent notches 23b and 26b and notch 17b is adjacent notches 22b and 25b. In addition, notch 20 is adjacent notch 28b. It will now be clear that the first fold 30 forms the back edge of the heel pocket which is shown in shadow in FIG. 6. In use, the garment is turned inside out and as shown in FIG. 7, a childs leg and foot are inserted within the foot portion. Accordingly, the heel pocket is stretched and the back edge, or first fold 30 is more clearly seen. The tongue area between the first fold 30 and second fold 32 forms substantially the heel pocket as best shown in FIG. 7. Further, from the second fold 32 to the remainder of the tongue towards the toe there is formed substantially the sole portion of the foot. As shown in FIG. 7, the sole of the foot is substantially within the portion of the tongue between fold 32 and the toe. Further, it will now be understood that the notches are positioned so that the first and second folds each define a line having a slight slope which is slightly further from the crotch end at the inner crotch edge than at the outer edge. In this manner, the outside edge of the toe of the garment is rounded out thereby to conform to a childs foot.

The right back tongue 13a is folded in a manner similar to that described in detail. A first fold is taken at notches 25a and 26a and a second fold is taken at points 1312 and 13c. The first and second folds form lines which are slightly closer to the crotch end at the outer edge than at the inner crotch edge. The right front extension 12a is sewn to the right back extension 13a so that the inner surfaces thereof are brought together and the outer surfaces are on the outside. It will now be clear that the left and right back panel extensions 14a and 13a are respectively longer than the left and right front panel extensions 12b and 12a with each of the extensions being measured from the crotch end. The reason for this greater length is that the first and second folds are taken in each of the back panel extensions.

As shown in FIG. 6, it will be understood that the seam connecting the front and back panels includes the folded portions so that the total seam may be somewhat thicker over the folded portions. As previously described, after all of the seams have beensewn, the garment is turned inside out so that the garment has a finished appearance on the outside surface. The entire finished garment is shown in FIG. 1 and it will be understood that the first fold 30 is now visible while the second fold 32 is hidden by the heel pocket as folded over.

While the garment illustrated in FIGS. 1-7 is particularly suited to a childs garment, it will be understood that the foot construction may be used in other garments requiring fully enclosed feet.

It will be understood by those skilled in the art that the above described embodiment is meant to be merely exemplary and that it is susceptible of modification and variation without departing from the spirit and scope of the invention.

What is claimed is:

1. A garment made of two-way stretch material having enclosed foot portions comprising a front panel and a back panel, each having inside and outside surfaces,

said front panel having a left and a right tongue-shaped extension respectively forming a part of the left and the right leg of the garment each having a toe end, said back panel having a left and a right tongueshaped extension respectively forming a part of the left and the right leg of the garment each having a toe end, said left and right back panel extensions being respectively longer as measured from the crotch end of the extensions than said left and right front panel extensions,

a first fold formed in each of said left and right back panel extensions with each first fold being in direction to tend to bring the inside surfaces of the respective back panels together,

a second fold formed in each of said left and right back panel extensions each closer to the toe end of its respective extension than the first fold, with each second fold being in direction to tend to bring the outside surfaces of the respective back panels together whereby each second fold is in opposite direction to that of its corresponding first fold to form a heel pocket and,

said left and right front extensions being sewn to said left and right back extensions respectively to tend to bring the inner surfaces of the extensions together thereby to form left and right enclosed foot portions respectively,

whereby in each leg portion (1) the first'fold forms the back edge of said heel pocket (2) between each first and second fold there is formed a substantial portion of said heel pocket and (3) from said second fold to the remainder of said extension in the direction of the toe end there is formed substantially the sole portion of said foot port on.

2. The garment of claim l'in which there are provided a pair of notches on each edge of each of the left and right back panel extensions, the pair of notches on an inner crotch edge of each back panel extension being formed slightly closer to the toe end of each extension than the pair of notches on the outer edge of each extension, and each of said back panel extensions extending slightly outward in width between each pair of notches.

3. The garment of claim 2 in which in said back panel extensions each of said first folds is taken between the uppermost notches closer to the crotch end of each extension and each of said second folds is taken between points defined by said outwardly extending width of each of said extensions.

4. The garment of claim 3 in which there is provided an additional notch formed on the crotch edge of each of said left and right back panel extensions closer to the crotch end of each extension than the remaining notches to define the positioning of the second fold of each extension.

5. The garment of claim 4 in which there is provided a pair of notches formed on the crotch edge of each of said left and right front panel extensions, and in which there is provided a single notch formed on the outer edge of each of said left and right front panel extensions, said notches being positioned so that when said front and back panel extensions are sewn together, the notches of the front panel extensions are adjacent corresponding notches of the pack panel extensions.

6. A method of making-a two way stretch garment from a front panel and a back panel in which said garment has enclosed foot portions which comprises cutting said front and back panels to form a left and a right tongue-shaped extension in each panel with said left and right back panel extensions being respectively longer as measured from the crotch end of the extensions than said left and right front panel extensions,

folding each of said left and right back panel extensions to form a first fold with each first fold being in direction to tend to bring inside surfaces of the respective back panels together,

folding each of said left and right back panel extensions to form a second fold closer to the toe end of its respective extension than said first fold with each second fold being in direction to tend to bring outside surfaces of the respective back panels together, and

sewing said left and right front extensions to said left and right back extensions respectively to tend to bring the inner surfaces of the extensions together to form left and right enclosed leg and foot portions.

7. The method of claim 6 in which there is provided the further step of turning said garment inside out after the left and right extensions have been sewn together.

References Cited UNITED STATES PATENTS 263,539 8/1882 Landenberger 2239 414,479 11/ 1889 Appleton 2-239 956,102 4/1910 Jones 21 14 1,982,579 11/1934 Earnshaw 2114 2,588,542 3/1952 Kunz 2-1 14 2,705,326 4/ 1955 Lahnstein et al. 283

FOREIGN PATENTS 329,355 11/1'920 Germany.

JORDAN FRANKLIN, Primary Examiner.

H. H. HUNTER, Assistant Examiner. 

1. A GARMENT MADE OF TWO-WAY STRETCH MATERIAL HAVING ENCLOSED FOOT PORTIONS COMPRISING A FRONT PANEL AND A BACK PANEL, EACH HAVING INSIDE AND OUTSIDE SURFACES, SAID FRONT PANEL HAVING A LEFT AND A RIGHT TONGUE-SHAPED EXTENSION RESPECTIVELY FORMING A PART OF THE LEFT AND THE RIGHT LEG OF THE GARMENT EACH HAVING A TOE END, SAID BACK PANEL HAVING A LEFT AND A RIGHT TONGUESHAPED EXTENSION RESPECTIVELY FORMING A PART OF THE LEFT AND THE RIGHT LEG OF THE GARMENT EACH HAVING A TOE END, SAID LEFT AND RIGHT BACK PANEL EXTENSIONS BEING RESPECTIVELY LONGER IS MEASURED FROM THE CROTCH END OF THE EXTENSIONS THAN SAID LEFT AND RIGHT FRONT PANEL EXTENSIONS, A FIRST FOLD FORMED IN EACH OF SAID LEFT AND RIGHT BACK PANEL EXTENSIONS WITH EACH FIRST FOLD BEING IN DIRECTION TO TEND TO BRING THE INSIDE SURFACES OF THE RESPECTIVE BACK PANELS TOGETHER, A SECOND FOLD FORMED IN EACH OF SAID LEFT AND RIGHT BACK PANEL EXTENSIONS EACH CLOSER TO THE TOE AND OF ITS RESPECTIVE EXTENSION THAN THE FIRST FOLD, WITH EACH SECOND FOLD BEING IN DIRECTION TO TEND TO BRING THE OUTSIDE SURFACES OF THE RESPECTIVE BACK PANELS TOGETHER WHEREBY EACH SECOND FOLD IS IN OPPOSITE DIRECTION TO THAT OF ITS CORRESPONDING FIRST FOLD TO FORM A HEEL POCKET AND, SAID LEFT AND RIGHT FRONT EXTENSIONS BEING SEWN TO SAID LEFT AND RIGHT BACK EXTENSIONS RESPECTIVELY TO TEND TO BRING THE INNER SURFACES OF THE EXTENSIONS TOGETHER THEREBY TO FORM LEFT AND RIGHT ENCLOSED FOOT PORTIONS RESPECTIVELY, WHEREBY IN EACH LEG PORTION (1) THE FIRST FOLD FORMS THE BACK EDGE OF SAID HEEL POCKET (2) BETWEEN EACH FIRST AND SECOND FOLD THERE IS FORMED A SUBSTANTIAL PORTION OF SAID HEEL POCKET AND (3) FROM SAID SECOND FOLD TO THE REMAINDER OF SAID EXTENSION IN THE DIRECTION OF THE TOE END THERE IS FORMED SUBSTANTIALLY THE SOLE PORTION OF SAID FOOT PORTION. 